Oxygen generator system and method of operating the same

Abstract

An oxygen generating system includes an oxygen generator having an oxygen ion conducting honeycomb structure and a heat exchanger thermally coupled to the oxygen generator. The system also includes a heater thermally coupled to the oxygen generator and a control module coupled to the oxygen generator and the heater. The control module monitors one or more of the system parameters and dynamically controls the oxygen generating system in response to the one or more system parameters such as, for example, varying the speed of a draft fan in the outlet waste air stream. A method of operating an oxygen generating system includes initializing the oxygen generating system in response to an operation status request and generating oxygen in an oxygen ion conducting honeycomb structure in response to a desired oxygen flow rate input. The method further includes monitoring one or more oxygen generating system parameters and controlling the oxygen generating system in response to the one or more oxygen generating system parameters.

What is claimed is: 
     
       1. An oxygen generating system, comprising: an oxygen generator including an oxygen ion conducting structure;   a heat exchanger coupled to the oxygen generator;   a heater thermally coupled to the oxygen generator; and   a control module coupled to the oxygen generator and the heater, wherein the control module monitors one or more system parameters and dynamically controls the operation of the oxygen generating system in response to the one or more system parameters.   
     
     
       2. The oxygen generating system of claim 1, wherein the oxygen ion conducting structure is a honeycomb structure. 
     
     
       3. The oxygen generating system of claim 2, wherein the oxygen ion conducting honeycomb structure includes a first plurality of channels which extend through a first face and a second face of the honeycomb structure and a second plurality of channels substantially parallel to the first plurality of channels, wherein the second plurality of channels are closed at the first face and the second face, respectively. 
     
     
       4. The oxygen generating system of claim 1, wherein the oxygen ion conducting structure comprises a ceramic. 
     
     
       5. The oxygen generating system of claim 4, wherein the ceramic comprises a stabilized bismuth oxide. 
     
     
       6. The oxygen generating system of claim 1, wherein the heater comprises at least one flat plate heater in proximity to the oxygen generator for elevating a temperature of the oxygen generator to a desired temperature range for optimal oxygen generating system performance. 
     
     
       7. The oxygen generating system of claim 1, further comprising a power supply coupled to the oxygen generator and the control module, wherein the power supply provides an appropriate input voltage and input current to the oxygen generator in response to one or more control signals from the control module. 
     
     
       8. The oxygen generating system of claim 7, further comprising an on/off/standby module coupled to the control module, wherein the on/off/standby module is operable to send an operational status signal to the control module to thereby place the oxygen generating system in either an "on" mode, an "off" mode, or a "standby" mode, respectively. 
     
     
       9. The oxygen generating system of claim 8, wherein the control module supplies a control signal to the power supply and the heater when the oxygen generating system is in the "on" mode, and supplies a control signal to the heater in the "standby" mode, thereby maintaining an optimal operating temperature for the oxygen generator during the "standby" mode for an efficient and substantially quick generation of oxygen when a user changes the oxygen generating system from the "standby" mode to the "on" mode. 
     
     
       10. The oxygen generating system of claim 1, further comprising a filter coupled to a source gas input port on the heat exchanger, wherein the filter substantially prevents an introduction of foreign matter into the oxygen generating system. 
     
     
       11. The oxygen generating system of claim 1, further comprising a safety valve coupled to the control module and within an outlet oxygen flow path from the heat exchanger, wherein the control module is operable to activate the safety valve and divert the oxygen generated by the oxygen generator away from a user if one or more performance parameters either exceeds or falls below a predetermined threshold. 
     
     
       12. The oxygen generating system of claim 11, wherein the safety valve comprises a solenoid-activated valve. 
     
     
       13. The oxygen generating system of claim 1, further comprising a draft module coupled to the control module and within an outlet waste gas flow path from the heat exchanger, wherein the draft module is operable to vary an amount of draft via the control module in response to one or more system parameters within the oxygen generating system, thereby maintaining the oxygen generator within an optimal temperature range. 
     
     
       14. The oxygen generating system of claim 13, wherein the draft module comprises a variable speed draft fan coupled to the control module, wherein when a temperature of the oxygen generator exceeds a first predetermined threshold, the draft fan speed is increased by the control module to thereby decrease the temperature of the oxygen generator, and wherein when the temperature of the oxygen generator falls below a second predetermined temperature threshold, the control module decreases the speed of the draft fan to thereby increase the temperature of the oxygen generator. 
     
     
       15. The oxygen generating system of claim 1, further comprising a display coupled to the control module for providing one or more visual indicia of one or more operating parameters of the oxygen generating system. 
     
     
       16. The oxygen generating system of claim 15, wherein the display further comprises one or more lights for providing a colored status indication of system operation to a user. 
     
     
       17. The oxygen generating system of claim 1, further comprising a peripheral input mechanism coupled to the control module for inputting one or more desired performance parameters into the oxygen generating system. 
     
     
       18. The oxygen generating system of claim 1, further comprising a modem coupled to the control module for transmitting one or more performance parameters monitored by the control module to a remote site for evaluation or trending purposes. 
     
     
       19. The oxygen generating system of claim 18, wherein the modem is further operable to receive an incoming call and access one or more performance parameters monitored by the control module. 
     
     
       20. The oxygen generating system of claim 1, wherein the control module further comprises a processor for monitoring the one or more system parameters monitored by the control module. 
     
     
       21. The oxygen generating system of claim 20, further comprising a memory coupled to the processor for storing one or more of the system parameters monitored by the processor. 
     
     
       22. The oxygen generating system of claim 21, further comprising a modem coupled to the processor, wherein the modem is operable to transmit one or more of the system parameters stored in the memory to a remote site for analysis or trending purposes. 
     
     
       23. The oxygen generating system of claim 22, wherein the modem is further operable to achieve a call from a remote site and access the one or more system parameters within the memory for analysis purposes. 
     
     
       24. A method of operating an oxygen generating system, comprising the steps of: initializing the oxygen generating system in response to an operation status request;   generating oxygen in an oxygen ion conducting honeycomb structure in response to a desired oxygen flow rate input;   monitoring one or more oxygen generating system parameters; and   controlling the oxygen generating system in response to the one or more oxygen generating system parameters.   
     
     
       25. The method of claim 24, wherein initializing the oxygen generating system comprises providing power to the honeycomb structure for the generation of oxygen when the operation status request indicates an ON mode. 
     
     
       26. The method of claim 25, wherein initializing the oxygen generating system further comprises providing power to a heater which provides heat to the honeycomb structure if a system parameter indicates the honeycomb structure is below a predetermined temperature threshold. 
     
     
       27. The method of claim 24, wherein initializing the oxygen generating system comprising providing power to a heater and limiting power to a power supply when the operation status request indicates a STANDBY mode, wherein the honeycomb structure is maintained substantially within an optimal temperature range although substantially no oxygen is being generated. 
     
     
       28. The method of claim 24, wherein initializing the oxygen generating system comprises: initiating a flow from an output of the honeycomb structure; and   supplying heat to the honeycomb structure to place the honeycomb structure within an optimal temperature range, wherein the flow aids in providing a uniform heating of the honeycomb structure.   
     
     
       29. The method of claim 24, wherein generating oxygen comprises supplying an input current to the honeycomb structure in response to the desired oxygen flow rate input. 
     
     
       30. The method of claim 24, wherein monitoring one or more oxygen generating system parameters comprises evaluating one or more sensors within the oxygen generating system, wherein the one or more sensors measure a status or parametric value reflecting an operation status of the oxygen generating system. 
     
     
       31. The method of claim 30, wherein the parametric values are selected from the group including a temperature, an oxygen purity level, a flow rate, an input voltage and an input current. 
     
     
       32. The method of claim 24, wherein the steps of monitoring one or more parameters and controlling the oxygen generating system in response to the one or more parameters comprises the steps of: determining whether waste gases are within a predetermined temperature range; and   increasing a flow rate of the outlet waste gas if the outlet waste gas temperature exceeds the predetermined temperature range.   
     
     
       33. The method of claim 32, further comprising the step of decreasing the flow rate of the outlet waste gas if the outlet waste gas temperature is less than the predetermined temperature range. 
     
     
       34. The method of claim 32, further comprising: determining whether the flow rate of the outlet waste gas is greater than a predetermined temperature threshold if the outlet waste gas temperature falls within or exceeds the predetermined temperature range; and   adding heat to the honeycomb structure if the flow rate of the outlet waste gas is less than the predetermined flow threshold and the outlet waste gas temperature is less than the predetermined temperature range.   
     
     
       35. The method of claim 32, wherein increasing the flow rate of the outlet waste gas comprises increasing the draft fan speed. 
     
     
       36. The method of claim 33, wherein decreasing the flow rate of the outlet waste gas comprises decreasing the draft fan speed. 
     
     
       37. The method of claim 24, wherein the steps of monitoring one or more parameters controlling the oxygen generating system in response to the one or more parameters comprises the steps of: determining whether an outlet oxygen purity level exceeds a predetermined purity threshold; and   activating a safety valve to divert a flow of the outlet oxygen from the patient if the outlet oxygen purity level is less than the predetermined purity threshold.   
     
     
       38. The method of claim 24, wherein the steps of monitoring one or more parameters and controlling the oxygen generating system in response to the one or more parameters comprises the steps of: determining whether an outlet oxygen purity level exceeds or falls below a predetermined purity threshold; and   activating a light of the oxygen generating system in response to the determination to thereby provide a visual indication of a condition status of the oxygen generating system.   
     
     
       39. The method of claim 24, wherein the steps of monitoring one or more parameters and controlling the oxygen generating system in response to the one or more parameters comprising the steps of: determining whether an outlet oxygen purity level exceeds or falls below a predetermined purity threshold; and   providing an audible signal in response to the determination to thereby provide an audible indication of a condition status of the oxygen generating system.   
     
     
       40. The method of claim 24, further comprising transmitting the one or more system parameters to a remote site for evaluation purposes. 
     
     
       41. The method of claim 40, wherein the step of transmitting the one or more system parameters to a remote site comprises: saving the one or more system parameters in a memory;   accessing the oxygen generating system with a modem; and   transmitting the system parameters from the memory to the remote site via the modem and a data link.   
     
     
       42. The method of claim 24, further comprising accessing the one or more system parameters from a remote site for evaluation purposes. 
     
     
       43. The method of claim 42, wherein the step of accessing the one or more system parameters from a remote site comprises: saving the one or more system parameters in a memory;   accessing the oxygen generating system with a modem; and   viewing the system parameters within the memory from the remote site via the modem and a data link.